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Related Experiment Video

Updated: Oct 25, 2025

A Soft Tooling Process Chain for Injection Molding of a 3D Component with Micro Pillars
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A Review on Microcellular Injection Moulding.

Yifei Ding1, Mohammed H Hassan1, Otto Bakker1

  • 1Department of Mechanical, Aerospace and Civil Engineering, The University of Manchester, Manchester M13 9PL, UK.

Materials (Basel, Switzerland)
|August 7, 2021
PubMed
Summary

Microcellular injection moulding (MuCell) uses supercritical fluids to create lightweight polymer parts. This review explores strategies to enhance surface appearance and mechanical properties for wider adoption.

Keywords:
MuCell®mechanical propertiesmicrocellular injection mouldingpolymer processingprocessing parameterssurface quality

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Area of Science:

  • Polymer Science and Engineering
  • Materials Processing

Background:

  • Microcellular injection moulding (MuCell) employs supercritical fluids (CO2 or N2) for lightweight product manufacturing.
  • Growing demand for eco-friendly processes and high-performance lightweight materials drives interest in MuCell technology.
  • Current limitations include suboptimal surface finish and insufficient mechanical properties, hindering widespread application.

Purpose of the Study:

  • To provide a comprehensive review of the MuCell process, its characteristics, and recent advancements.
  • To critically examine strategies for improving surface quality and mechanical properties.
  • To review simulation approaches and identify future research directions.

Main Methods:

  • Literature review of microcellular injection moulding processes, bubble nucleation and growth dynamics.
  • Analysis of strategies impacting surface and mechanical properties, linking them to processing parameters and morphology.
  • Review of simulation software (Moldex3D, Moldflow) and underlying mathematical models.

Main Results:

  • MuCell technology offers a pathway to lightweight polymer products using supercritical fluids.
  • Key challenges involve enhancing surface aesthetics and mechanical strength.
  • Processing parameters, morphology, and material properties are intricately linked.

Conclusions:

  • Further research is needed to overcome current limitations in surface quality and mechanical performance.
  • Optimizing processing parameters and understanding morphology-structure-property relationships are crucial for MuCell advancement.
  • Advanced simulation tools require further development to accurately predict MuCell outcomes.